Bugatti Creates A Brake Caliper From A 3-D Printer

Bugatti Creates A Brake Caliper From A 3-D Printer

While the main material used for the additive production of vehicle components to date has been aluminum, the new brake caliper is made from titanium.


With its Veyron and Chiron super sports cars, Bugatti developers have succeeded in designing a brake caliper that can be produced by 3-D printing. While the main material used for the additive production of vehicle components to date has been aluminium, the new brake caliper is made from titanium. The company says this is the world’s largest functional component produced from titanium using a 3-D printing processes.

This new milestone in the development of 3-D printing was reached in cooperation with Laser Zentrum Nord of Hamburg, part of the Fraunhofer research organization since the beginning of the year. Vehicle trials for the use of the 3-D titanium brake caliper in series production are expected to start in the first half of the year.

“Vehicle development is a never-ending process. This is particularly true at Bugatti,” said Frank Götzke, head of new technologies in the Technical Development Department of Bugatti Automobiles S.A.S. “In our continuing development efforts, we are always considering how new materials and processes can be used to make our current model even better and how future vehicles of our brand could be designed.

“As our performance data are often at the physical limits, we are especially demanding,” added Götzke. “This is why Bugatti always goes at least one step further than other manufacturers in the development of technical solutions.”

Götzke has worked for the Volkswagen group for more than 22 years. He joined Bugatti in 2001 and played a key role in the development of the Veyron as head of chassis development and in the development of the Chiron1 in his current position.

Bugatti says it currently uses some of the most powerful brakes in the world on the new Chiron. The brake calipers, it adds, were an entirely new development. They are forged from a block of high-strength aluminium alloy. With eight titanium pistons on each of the front calipers and six on each of the rear units, these also are the largest brake calipers currently installed on a production vehicle. The brake calipers of the Chiron are produced using bionic principles on the basis of a natural model. The new architecture combines minimum weight with maximum stiffness. The inspiration for the design and mode of operation of the brakes was taken from motorsports.

With the newly developed titanium brake caliper from the 3-D printer, Bugatti is now going one step further and breaking new ground. This particular titanium alloy, with the scientific designation of Ti6AI4V, is mainly used in the aerospace industry. The material offers considerably higher performance than aluminium. The new titanium brake caliper, which is 41 cm long, 21 cm wide and 13.6 cm high, weighs only 2.9 kg. In comparison with the aluminium component currently used, which weighs 4.9 kg, Bugatti could therefore reduce the weight of the brake caliper by about 40 percent at the same time as ensuring even higher strength by using the new part.

The first trials for use in production vehicles are due to be held in the first half of the year; the time schedule is still to be finalized. At that stage, the engineer promises that it will be possible to considerably shorten production times, especially for machining.

You May Also Like

Mercedes-Benz ABC Suspensions

The system provides great ride & handling, but it can be complicated to service if you do not have the right training.

Mercedes-Benz uses two different adjustable suspension systems in its vehicles – Airmatic and Active Body Control (ABC). Airmatic, as the name implies, is its air suspension system which we discussed back in April of this year. ABC uses hydraulic fluid at tremendous pressures to actively change the stiffness of the springs inside the shock assemblies, changing vehicle dynamics and ride height. This can be done automatically based on sensor inputs and module programming, or at the push of a button located near the shifter.

Timing The BMW N53 And N54

The BMW N53 (naturally aspirated) and N54 (turbocharged) engines were among the first BMW engines to come with variable valve timing on the intake and exhaust camshafts. The N53 and N54 straight-six has unfairly earned a bad reputation for reliability with technicians due to timing chain and variable valve timing problems. The reputation comes from

European Oil Specifications

If a manufacturer introduces a new vehicle with a new ACEA sequence specification, the oil must be on shelves.

Jaguar Air Ride Diagnostics

The 2004-2009 Jaguar XJ8 and XJR were the first and last Jaguars with four-corner air ride suspension.

Servicing Mercedes-Benz ADAS Systems

A great piece of advice is not to erase codes to see if they come back.

Other Posts

Auto Value, Bumper to Bumper Ultimate Vehicle Giveaway

Two lucky technicians will win a vehicle of their choice this spring.

SMP Expands Hybrid and EV Product Offering

Standard is prepared to meet the demand of the growing hybrid and EV population with over 4,000 parts available for 150 models.

General Tire Launches Spring Passenger Tire Promotion

Consumers who purchase a set of 4 qualifying passenger General Tires can get up to a $70 prepaid Visa card.

ASE, Goodguys Partner to Promote Education, Careers

They are joining forces to showcase the wide array of career paths in the world of hot rodding and automotive service.